Isuzu KB P190. Manual - part 184

BRAKES  5C-37 

 

  REMOVAL AND INSTALLATION OF DISC PAD 

 

 

 

 

RUW55CSH001501 

 

Removal Steps 

1. Lock Bolt 
Remove the lock bolt from the caliper. 
Note: 
Don’t remove the brake hose from the caliper when 
replacing pads. 
 

 

 
 

2.  Rotate the Caliper Upward 
Remove the caliper from the support bracket and move the 
caliper to the upper link or the frame. 
Note: 
While caliper is removed from the support bracket, never 
step on the brake pedal or the piston will protrude rapidly.
 

 

 

 

RUW55CSH001601 

 
 

3.  Pad Assembly with Shim 
Remove the pad assembly with the shim. 
Mark the pad locations if they are to be reinstalled. 
 

 

 
 

4. Clip; Pad 
Discard the used clip and install a new one. 
 

5C-38  BRAKES 

 

 

Installation Steps 

1. Clip; Pad 

2.  Pad Assembly with Shim 
After attaching the pad assembly with the shim to the support
bracket, position the wear indicator to the lower side of the
inner pad and position the wear indicator to the upper side of 
the outer pad. 

 

 

RUW55CSH001701 

 
 

3. Caliper Assembly 
Lower the caliper into its original position. 
Do not damage the flexible hose by twisting or pulling it. 
 

 

 

 

RUW55CSH000201 

 

4. Lock Bolt 
Attach the lock bolt to the caliper. 
Torque N

⋅m (kgf⋅m/lb⋅ft)

32 - 40 (3.3 – 4.1 / 24 - 30) 

 

 
 

BRAKES  5C-39 

  DISASSEMBLY 

 

CALIPER ASSEMBLY 

 

 

Disassembly Steps 

 

1. Bleeder with cap 

▲ 2. Piston 
 

3. Dust seal; piston 

 

4. Ring seal 

 

5. Body; caliper 

 

 

 

 

 
 
 
 

 

Important Operations 

 

 
 

2.  Piston (with Ring Seal) 
Insert a block of wood into the caliper and force out the piston 
by blowing compressed air into the caliper at the flexible hose
attachment. 
This procedure must be done prior to removal of the dust seal.
 
CAUTION: 
Do not place your fingers in front of the piston in an
attempt to catch or protect it when applying compressed 
air. 

 

5C-40  BRAKES 

  INSPECTION AND REPAIR 

 
Make necessary correction or parts replacement if wear damage or any other abnormal conditions are found 
through inspection. 
 
 

 

• Rotor 
• Caliper body 
• Cylinder bore 
• Piston 
• Support bracket 
• Lock bolt 
• Guide pin 

 

 

 

Visual Check 

Inspect the following parts for wear, bending, distortion, 
cracking, corrosion, or other abnormal conditions. 
 

 

 

 

 

Rotor 

•  Thickness (t) 

mm (in)

Standard

Replacement thickness

(Discard)

4

×2

(Except HIGH RIDE)

26.0 (1.024)

24.6 (0.969)

4

×2

(HIGH RIDE)

4

×4

27.0 (1.063)

25.6 (1.008)

 

 

 

• Run 

out 

Limit mm 

(in)

0.075 (0.0029) 

 
Before inspection, adjust the wheel bearing correctly. 
Using a dial gauge, measure the run-out at the 10 mm inside 
position from the rotor out-side edge of the disc pad contact 
surface. 
 

 

 

•  Parallelism (Total circumferential thickness variation) 
Limit mm 

(in)

0.023 (0.0009) 

 
Contact surface must be within 0.023 mm at the 10 mm inside 
position from rotor-out side edge. 
(Measurement; should be measured at more than 8 positions
in circumferential direction.)